Methods and apparatuses for removing material from discrete areas on a semiconductor wafer

ABSTRACT

Methods and apparatuses for removing material from discrete areas on a semiconductor wafer are described. In one implementation, an etchant applicator is provided having a tip portion. Liquid etchant material is suspended proximate the tip portion and the etchant applicator is moved, together with the suspended liquid, sufficiently close to a discrete area on a wafer to transfer liquid etchant onto the discrete area. In various embodiments the tip portion can comprise fluid permeable materials, fluid-absorbent materials, and/or wick assemblies. An exhaust outlet can be provided operably proximate the tip portion for removing material from over the wafer. The tip portion can be moved to touch the discrete area.

RELATED PATENT DATA

This patent resulted from a divisional application of U.S. application Ser. No. 09/032,212, filed on Feb. 27, 1998 now U.S. Pat. No. 6,153,352.

TECHNICAL FIELD

This invention relates to methods and apparatuses for removing material from discrete areas on a semiconductor wafer, and in particular to methods and apparatuses for removing material from over alignment marks on a wafer.

BACKGROUND OF THE INVENTION

It is sometimes desirable in semiconductor device manufacturing to remove material from over discrete wafer areas, without exposing other wafer areas to the etchant solutions. One type of discrete area includes alignment marks which are used to align wafers during processing. Alignment marks are preferably kept substantially clear of contaminants or material so that processing equipment can easily locate them. Alignment marks can get covered with a variety of material including photoresist, etched substrate material, and chemical mechanical polishing slurry or a variety of thin films. When alignment marks get covered with material, it is desirable to remove the material. Methods and apparatuses for removing material from over alignment marks are described in U.S. Pat. No. 5,271,798, which is assigned to the assignee of this document, the disclosure of which is incorporated by reference.

This invention arose out of concerns associated with providing improved methods and apparatuses for removing material from discrete areas, e.g. alignment marks, on a semiconductor wafer.

SUMMARY OF THE INVENTION

Methods and apparatuses for removing material from discrete areas on a semiconductor wafer are described. In one implementation, an etchant applicator is provided having a tip portion. Liquid etchant material is suspended proximate the tip portion and the etchant applicator is moved, together with the suspended liquid, sufficiently close to a discrete area on a wafer to transfer liquid etchant onto the discrete area. In various embodiments the tip portion can comprise fluid permeable materials, fluid-absorbent materials, and/or wick assemblies. An exhaust inlet can be provided operably proximate the tip portion for removing material from over the wafer. The tip portion can be moved to touch the discrete area.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the following accompanying drawings.

FIG. 1 is a top plan view of a semiconductor wafer showing an exemplary discrete area.

FIG. 2 is a diagrammatic side sectional view of an exemplary discrete area comprising alignment marks.

FIG. 3 is a view of the FIG. 2 wafer fragment at a processing step subsequent to that shown in FIG. 2.

FIG. 4 is a side elevational view of an etchant applicator constructed in accordance with one embodiment of the present invention.

FIG. 5 is a view of a tip portion of the FIG. 4 applicator in accordance with one embodiment of the invention.

FIG. 6 is a view of a tip portion of the FIG. 4 applicator in accordance with another embodiment of the invention.

FIG. 7 is a view of a tip portion of the FIG. 4 applicator in accordance with another embodiment of the invention.

FIG. 8 is a view of a tip portion of the FIG. 4 applicator in accordance with another embodiment of the invention.

FIG. 9 is a view of a tip portion of the FIG. 4 applicator, undergoing processing in accordance with one or more embodiments of the present invention.

FIG. 10 is a view of a tip portion of the FIG. 4 applicator, undergoing processing in accordance with one embodiment of the present invention.

FIG. 11 is a view of a tip portion of the FIG. 4 applicator, positioned proximate the FIG. 3 wafer fragment.

FIG. 12 is a view of the FIG. 3 wafer fragment undergoing processing in accordance with one embodiment of the invention.

FIG. 13 is a view of the FIG. 3 wafer fragment undergoing processing in accordance with one embodiment of the invention.

FIG. 14 is a view of portions of an etchant applicator constructed in accordance with one embodiment of the invention.

FIG. 15 is a view of a wafer fragment undergoing processing in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).

Referring to FIGS. 1 and 2, a semiconductor wafer is shown generally at 20 and comprises a semiconductive substrate 21. In the context of this document, the term “semiconductive substrate” is defined to mean any construction comprising semiconductive material, including, but not limited to, bulk semiconductive materials such as a semiconductive wafer (either alone or in assemblies comprising other materials thereon), and semiconductive material layers (either alone or in assemblies comprising other materials). The term “substrate” refers to any supporting structure, including, but not limited to, the semiconductive substrates described above. Substrate 21 includes a discrete area 22 from which material is desired to be removed. Discrete area 22 can comprise any area from over or within which material is desired to be removed, while not subjecting other substrate areas to the removal media or etchant which is used. In the preferred embodiment, discrete area 22 comprises an area containing alignment marks.

Referring to FIG. 2, a layer 24 is formed over substrate 21 and patterned to define alignment marks 26 which, in this example, are formed over a discrete area of wafer 20.

Referring to FIG. 3, a material has been formed over the wafer and the surface has been planarized, typically by using a chemical mechanical planarization process leaving residue 28 over the substrate and within alignment marks 26. Residue 28 can comprise any residual material. In this example, such material can include chemical mechanical planarization process slurry material, a refractory metal, a photoresist, dielectric material, polysilicon material, e.g., any residue from a semiconductor manufacturing process which might be present in or over alignment marks 26. In a preferred embodiment, residue 28 comprises an oxide film which is subsequently removed.

Referring to FIG. 4, an etchant applicator in accordance with one embodiment of the invention is shown generally at 30 and includes a stem portion 32 and a tip portion 34 connected therewith. Stem portion 32 can be dimensioned to be gripped or held by an individual during use. Stem portion 32 can also be configured for automated use by processing equipment. Liquid etchant material is provided over tip portion 34 which can then be used to treat a discrete area on a wafer. Any liquid etchant material can be used, and an exemplary material comprises hydrofluoric acid utilized in concentrations which are normally used during etching of various materials.

Referring to FIGS. 5-8, four exemplary tip portions are shown respectively at 34 a, 34 b, 34 c and 34 d.

Referring to FIG. 5, tip portion 34 a comprises a fluid-permeable material 36. As used in the context of this document, the term “fluid-permeable material” is intended to include materials which are capable of holding or being penetrated with liquid etchant materials. Penetration can occur through openings, pores, interstices, spaces and/or other similar structure in the material. Such materials include those through which liquid etchant material diffuses, pervades, absorbs, and/or saturates. Accordingly, material 36 can include fibrous material such as a plurality of fibrous members or fibers 38. Exemplary fibrous members include Teflon® or Gortex® fibers.

Referring to FIG. 6, tip portion 34 b comprises a fluid-absorbent material 40. As used in the context of this document, the term “fluid-absorbent material” is intended to include materials which are capable of taking up or drinking in liquid etchant material.

Referring to FIG. 7, tip portion 34 c includes a body 42 having a hollow opening 44 into a cavity in which a portion of a droplet 46 is disposed. A projected portion 48 of droplet 46 projects outward of hollow opening 44 and is suspended or clung onto tip portion 34 c for purposes which will become evident below.

Referring to FIG. 8, tip portion 34 d comprises a wick assembly 50 having a plurality of fibers or fibrous members 52. Wick assembly 50 comprises material which is configured to receive an amount of liquid etchant through wicking action. Accordingly, exemplary materials for wick assembly 50 include fluid-permeable materials and fluid-absorbent materials such as those mentioned above.

Referring to FIGS. 9 and 10, an amount of liquid etchant 54 is provided over tip portions 34, 34 b respectively. Tip portion 34 can include any of the above-described tip portions (FIGS. 5-8), and liquid etchant 54 can be provided thereover in any suitable way. For example, liquid etchant 54 can be absorbed into, within, onto or through the material comprising tip portion 34. In this way, liquid etchant material can be clung onto, supported by, or suspended by the tip portion. In FIG. 10, liquid etchant material is provided over tip portion 34 b by dipping or immersing some or all of the tip portion into an amount of liquid etchant 54. The liquid etchant is absorbed by tip portion 34 b. As the liquid etchant is absorbed by tip portion 34 b, the illustrated pores (not specifically designated) expand slightly in a sponge-like fashion.

Referring to FIG. 11, the etchant applicator, including tip portion 34 (not necessarily shown to scale), is moved into proximity with a discrete area 22.

Referring to FIGS. 12 and 13, liquid etchant material 54 is transferred from tip portion 34 onto discrete area 22. In a first embodiment (FIG. 12), tip portion 34 is moved or placed, together with the suspended or clung liquid etchant material, sufficiently close to discrete area 22, e.g. touching the discrete area, to transfer at least some of material 54 onto the discrete area. Such constitutes one example of placing the tip portion into proximity with discrete area 22 sufficiently to bring at least some of the etchant material into physical contact with discrete area 22. Removing tip portion 34 thereafter leaves at least some etchant material 54 behind on the wafer.

Referring to FIG. 13, tip portion 34 c is moved sufficiently close to discrete area 22 to transfer at least some of the suspended or clung liquid etchant material 54 onto discrete area 22. In this example, the tip portion is placed into proximity with the discrete area without physically touching or contacting the discrete area. Removal of the tip portion thereafter results in at least some of the etchant material being left behind on the wafer. Tip portion 34 c is used in this example for illustrative purposes only. Other above-described tip portions could be used in this manner.

Referring to FIG. 14, a liquid etchant applicator assembly in accordance with another embodiment of the invention is shown generally at 56 and includes a tip portion 34 and an exhaust outlet 58 proximate tip portion 34. Exhaust outlet 58 is configured to remove material from around tip portion 34 during processing. The removed material can include either liquid or gaseous material which can be a by-product from the processing taking place. During treatment of a wafer portion 20 (shown in phantom), exhaust outlet 58 removes material from over the discrete area. Although not specifically shown, exhaust outlet 58 can have inlets through which material is provided for processing the wafer. In the illustrated example, the exhaust outlet comprises a vacuum device which is configured to remove gaseous material. For example, when processing with a liquid etchant material comprising hydrofluoric acid, fumes can often be generated which are removed through exhaust outlet 58. In the illustrated example, the exhaust outlet comprises a sheath 60 which can touch the wafer to form a seal therewith during removal of the desired material. In another embodiment, and one which does not necessarily require an exhaust outlet 58, a reservoir 62 is provided and is in fluid communication with tip portion 34. Accordingly, liquid etchant can be supplied to tip portion 34 without resort to dipping the tip portion into an amount of liquid etchant. Liquid etchant from reservoir 62 can be provided over tip portion 34 in any suitable fashion. Processing, of course, can take place as described above.

Referring to FIG. 15, etchant applicator 30 can be utilized to treat discrete area 22 of wafer 20 by dabbing (arrow A) the area with the tip portion, or by drawing (arrow B) applicator 30 across or through a desired discrete area. The wafer can be dabbed repeatedly with the applicator. In the case where applicator 30 is used to dab the wafer, and where the liquid etchant material comprises hydrofluoric acid, such dabbing can take place for no more than about one or two seconds. Longer treatment times can be utilized such as contacting the wafer for one minute or longer.

Methods and apparatuses of the above-described invention enable liquid etchant material, such as hydrofluoric acid, to be applied over a surface of a wafer with precision and accuracy. Such provides for the dispensing of a small amount of chemical etchant onto a surface to be etched in a highly localized area. Chemicals can be dispensed with little or no equipment to regulate flows, such as in conventional nozzle-like fluid dispensing apparatuses. In addition, the etchant applicator can be disposable and/or can contain its own fluid reservoir, thereby resulting in considerable equipment savings.

In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. 

What is claimed is:
 1. A liquid etchant applicator assembly comprising: a fluid absorbent tip portion having a first diameter and configured to receive an amount of liquid etchant material; a sheath having an exhaust outlet configured to remove material from around the tip portion over a wafer; a stem tube having a second diameter less than the first diameter and in fluid communication with the tip portion, the stem tube suspending the tip portion at least partially within the sheath and the second diameter of the stem tube being within the sheath; an etchant reservoir tube having a third diameter less than the second diameter, the reservoir tube being in fluid communication with the stem tube and the third diameter of the reservoir tube being outside the sheath; and a liquid etchant reservoir in fluid communication with the etchant reservoir tube.
 2. The liquid etchant applicator assembly of claim 1, wherein the exhaust outlet further comprises a vacuum device configured to remove gaseous material.
 3. The liquid etchant applicator assembly of claim 1, wherein the sheath is configured to touch a portion of the wafer.
 4. The liquid etchant applicator assembly of claim 1, wherein the fluid-absorbent tip portion comprises a fibrous wick.
 5. The liquid etchant applicator assembly of claim 1, wherein the liquid etchant comprises hydrofluoric acid.
 6. A liquid etchant applicator assembly comprising: a fluid absorbent tip portion configured to receive an amount of liquid etchant material, the absorbent tip portion having a diameter at a middle part that is greater than a diameter at an upper tapered part and greater than a diameter at a lower tapered part of the absorbent tip portion; a sheath having a side wall around the tip portion and a top wall over the tip portion; and a vacuum port through the sheath side wall, the vacuum port having an uppermost elevational extent lower than the sheath top wall, the vacuum port being configured to remove material from within the sheath around the tip portion over a wafer.
 7. The liquid etchant applicator assembly of claim 1, further comprising a vacuum device configured to remove gaseous material and attached to the vacuum port.
 8. The liquid etchant applicator assembly of claim 1, wherein the sheath is configured to touch a portion of the wafer.
 9. The liquid etchant applicator assembly of claim 6, further comprising a liquid etchant reservoir in fluid communication with the fluid-absorbent tip portion to replace the amount of liquid etchant after it is transferred to a discrete area of a wafer.
 10. The liquid etchant applicator assembly of claim 6, wherein the fluid-absorbent tip portion comprises a fibrous wick.
 11. The liquid etchant applicator assembly of claim 6, wherein the liquid etchant comprises hydrofluoric acid.
 12. A liquid etchant applicator assembly comprising: a fluid absorbent tip portion configured to receive an amount of liquid etchant material, the absorbent tip portion having a diameter at a middle part that is greater than a diameter at an upper tapered part and greater than a diameter at a lower tapered part of the absorbent tip portion; a sheath having a side wall around the tip portion and a top wall over the tip portion; a stem tube having a diameter less than the diameter of the tip portion at the middle part and in fluid communication with the tip portion, the stem tube suspending the tip portion within the sheath and the diameter of the stem tube being within the sheath; a vacuum port through the sheath side wall, the vacuum port having an uppermost elevational extent lower than the sheath top wall, the vacuum port being configured to remove material from within the sheath around the tip portion over a wafer; an etchant reservoir tube having a diameter less than the stem tube diameter, the reservoir tube being in fluid communication with the stem tube and the diameter of the reservoir tube being outside the sheath; and a liquid etchant reservoir in fluid communication with the etchant reservoir tube.
 13. The liquid etchant applicator assembly of claim 12, further comprising a vacuum device configured to remove gaseous material and attached to the vacuum port.
 14. The liquid etchant applicator assembly of claim 12, wherein the sheath is configured to touch a portion of the wafer.
 15. The liquid etchant applicator assembly of claim 12, wherein the fluid-absorbent tip portion comprises a fibrous wick.
 16. The liquid etchant applicator assembly of claim 12, wherein the liquid etchant comprises hydrofluoric acid. 